Liner hanger

ABSTRACT

An apparatus and method for forming or repairing a wellbore casing by radially expanding a tubular liner.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of, and is the National Stage filing for, PCT patent application serial no. PCT/US02/20477, filed on Jun. 26, 2002, the disclosure of which is incorporated herein by reference.

This application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/303,711, filed on Jul. 6, 2001, the disclosure of which is incorporated herein by reference.

This application is related to the following applications: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999 now U.S. Pat. No. 6,497,289, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, now U.S. Pat. No. 6,823,937, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, now U.S. Pat. No. 6,328,113, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, now U.S. Pat. No. 6,640,903, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, now U.S. Pat. No. 6,568,471, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, now U.S. Pat. No. 6,575,240, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, now U.S. Pat. No. 6,557,640, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, now U.S. Pat. No. 6,604,763, (10) PCT patent application Ser. No. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Jul. 18, 2000, (21) U.S. provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, filed on Feb. 20, 2001; (23) U.S. provisional patent application Ser. No. 60/262,434, filed on Jan. 17, 2001; (24) U.S. provisional patent application Ser. No. 60/259,486, filed on Jan. 3, 2001; and (25) U.S. provisional patent application Ser. No. 60/303,711, filed on Jul. 6, 2001, the disclosures of which are incorporated herein by reference.

This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7 1998, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. Pat. No. 6,640,903 which was filed as U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16/1999, (16) U.S. provisional patent application Ser. No. 60/438,828, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, which claims priority from provisional patent application Ser. No. 60/159,039, filed on 10/12/1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, which claims priority from provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. No. 60/455,051, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,711, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, which claims priority from provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/322,947, filed on Dec. 18, 2002, which claims priority from provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, which claims priority from provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, which claims priority from provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13, 2003, which claims priority from provisional patent application Ser. No. 60/262,434, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, which claims priority from U.S. provisional patent application Ser. No. 60/259,486, filed on Jan. 3, 2001, (31) U.S. provisional patent application Ser. No. 60/452,303, filed on Mar. 5, 2003, (32) U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No. 09/852,026, filed on May 9, 2001, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application Ser. No. 09/852,027, filed on May 9, 2001, as a divisional application of U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (35) PCT Application US02/25608, filed on Aug. 13, 2002, which claims priority from provisional application 60/318,021, filed on Sep. 7, 2001, (36) PCT Application US02/24399, filed on Aug. 1, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/313,453, filed on Aug. 20, 2001, (37) PCT Application US02/29856, filed on Sep. 19, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/326,886, filed on Oct. 3, 2001, (38) PCT Application US02/20256, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,740, filed on Jul. 6, 2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25, 2001, which is a divisional of U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent application Ser. No. 09/962,470, filed on Sep. 25, 2001, which is a divisional of U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, (now U.S. Pat. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11 1999, (41) U.S. patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, which is a divisional of U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed on Sep. 25, 2001, which is a divisional of U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser. No. 09/962,468, filed on Sep. 25, 2001, which is a divisional of U.S. patent application Ser. No. 09/523,468, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (44) PCT application US 02/25727, filed on Aug. 14, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/317,985, filed on Sep. 6, 2001, and U.S. provisional patent application Ser. No. 60/318,386, filed on Sep. 10, 2001, (45) PCT application US 02/39425, filed on Dec. 10, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/343,674, filed on Dec. 27, 2001, (46) U.S. utility patent application Ser. No. 09/969,922, filed on Oct. 3, 2001, (now U.S. Pat. 6,634,431 which issued Oct. 21, 2003), which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (47) U.S. utility patent application Ser. No. 10/516,467, filed on Dec. 10, 2001, which is a continuation application of U.S. utility patent application Ser. No. 09/969,922, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 which issued Oct. 21, 2003), which is a continuation-in-part application of U.S. Pat. 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BACKGROUND OF THE INVENTION

This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.

Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.

SUMMARY OF THE INVENTION

According to one example of the present invention, a method of coupling a radially expandable tubular member to a preexisting structure is provided that includes positioning the tubular member within the preexisting structure, injecting fluidic materials into the tubular member, sensing the operating pressure of the fluidic materials, and radially expanding the tubular member into contact with the preexisting structure when the sensed operating pressure exceeds a predetermined amount.

According to another example of the present invention, an apparatus for coupling a radially expandable tubular member to a preexisting structure is provided that includes a first tubular support member, an expansion cone assembly, an expansion cone launcher, and a shoe assembly. The first tubular support includes a first internal passage. The expansion cone assembly includes a second tubular support including a second internal passage operably coupled to the first internal passage one or more radial openings, and a first releasable coupling, one or more pressure relief valves positioned in corresponding ones of the radial openings, and an annular expansion cone coupled to the second tubular support. The expansion cone launcher is coupled to the annular expansion cone and the radially expandable tubular member. The shoe assembly includes a third tubular support member including a third internal passage operably coupled to the second internal passage and having a restriction, and a second releasable coupling releasably coupled to the first releasable coupling.

According to another example of the invention, a tubular liner is provided that includes a first tubular portion, a first tapered tubular portion coupled to the first tubular portion, a second tubular portion coupled to the first tapered tubular portion, a second tapered tubular portion coupled to the second tubular portion, and a third tubular portion coupled to the second tapered tubular portion.

According to another example of the invention, a method of coupling a radially expandable tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion device within the preexisting structure, and radially expanding the tubular member into contact with the preexisting structure using the expansion device, wherein the tubular member includes a first tubular portion, a first tapered tubular portion coupled to the first tubular portion, a second tubular portion coupled to the first tapered tubular portion, a second tapered tubular portion coupled to the second tubular portion, and a third tubular portion coupled to the second tapered tubular portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 1 a-1 d are fragmentary cross-sectional illustrations of an embodiment of a liner hanger.

FIGS. 2 a-2 d are fragmentary cross-sectional illustrations of the placement of the liner hanger of FIGS. 1 a-1 d into a wellbore.

FIGS. 3 a-3 d are fragmentary cross-sectional illustrations of the release of the bottom SSR plug from the apparatus of FIGS. 2 a-2 d.

FIGS. 4 a-4 d are fragmentary cross-sectional illustrations of the release of the top SSR plug from the apparatus of FIGS. 3 a-3 d.

FIGS. 5 a-5 c are fragmentary cross-sectional illustrations of the initiation of the radial expansion process for the apparatus of FIGS. 4 a-4 d.

FIGS. 6 a-6 c are fragmentary cross-sectional illustrations of the continuation of the radial expansion process for the apparatus of FIGS. 5 a-5 c.

FIGS. 7 a-7 c are fragmentary cross-sectional illustrations of the drilling out of the collar upon the completion of radial expansion process for the apparatus of FIGS. 6 a-6 c.

FIGS. 8 a and 8 b are cross sectional illustrations of an alternative embodiment of an expansion cone assembly for use in the apparatus of FIGS. 1 a-1 d.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

An apparatus and method for plastically deforming a tubular liner within a wellbore within a subterranean formation is provided. The apparatus and method thereby provides a system for coupling a radially expandable tubular liner to an open hole or cased section of a wellbore within a subterranean formation. Furthermore, in this manner, a wellbore casing, a pipeline, or a structural support may be formed or repaired using the present illustrative embodiments.

Referring initially to FIGS. 1 and 1 a-1 d, an embodiment of an apparatus 100 for radially expanding and plastically deforming a tubular liner includes a tubular hanger joint 105 coupled to a tubular expansion cone launcher 110. The tubular hanger joint 105 includes a first section 105 a, a first transition section 105 b, an intermediate section 105 c, a second transition section 105 d, and a second section 105 e. The outside diameter of the first and second sections, 105 a and 105 e, are preferably less than the outside diameter of the intermediate section 105 c. The intermediate section 105 c preferably further includes radially directed coupling elements 105 ca-105 cd affixed to the outside surface of the intermediate section 105 c for enhancing the connection of the tubular hanger joint 105 to a preexisting structure following the radial expansion of the tubular hanger joint using the apparatus 100.

The expansion cone launcher 110 includes an upper tubular portion 110 a, an intermediate tubular portion 110 b, and a lower tubular portion 110 c. In a preferred embodiment, the outside diameter of the upper portion 110 a is less than the outside diameter of the lower portion 110 c in order to facilitate the placement of the apparatus 100 within a wellbore, or other tubular member. In a preferred embodiment, the wall thickness of the intermediate portion 110 b is less than the wall thickness of the upper and lower portions, 110 a and 110 c, in order to facilitate the initiation of the radial expansion of the expansion cone launcher 110.

An expansion cone assembly 115 is positioned within the expansion cone launcher 110 that includes a tubular coupling 120 that includes a conventional threaded coupling element 120 a at one end for coupling the tubular coupling to a conventional support member and a threaded counterbore 120 b at another end for coupling the tubular coupling to an end of a first tubular support 125. The tubular coupling 120 further includes an internal passage 120 c for conveying fluidic materials.

The first tubular support 125 includes an internal passage 125 a for conveying fluidic materials and an annular flange 125 b, openings 125 ca and 125 cb, and a releasable coupling 125 d at another end. In an exemplary embodiment, the releasable coupling 125 d is a conventional collet assembly having a plurality of resilient collet fingers. A second tubular support 130 includes an opening 130 a at one end for receiving an end of the first tubular support 125, a counterbore 130 b, first and second shoulders, 130 c and 130 d, an inwardly directed annular flange 130 e, and a threaded connection 130 f at another end. An expansion cone 135 that mates with the interior surface of the expansion cone launcher 110 includes an opening 135 a and a counterbore 135 b at one end for receiving an end of the second tubular support 130 and receiving an annular spacer 140, respectively, a counterbore 135 c at another end for receiving the shoulder 130 c of the second tubular support, and an end face 135 d that mates with the shoulder 130 d of the second tubular support.

The annular spacer 140 is positioned receives an end of the first tubular support 125 and is positioned within the counterbore 135 b of the expansion cone 135 between the end face of the tubular coupling 120 and the end faces of the first tubular support and the counterbore of the expansion cone. An end of a third tubular support 145 is received within the counterbore 130 b of the second tubular support 130, and another end of the third tubular support abuts an end of a fourth tubular support 150. The fourth tubular support 150 includes one or more longitudinal passages, 150 a and 150 b, for conveying fluidic materials, and an end of the fourth tubular support mates with the annular flange 125 b of the first tubular support 125.

A fifth tubular support 155 includes an annular recess 155 a at an end that mates with the annular flange 130 e of the second tubular support 130, and another end of the fifth tubular support includes an annular recess 155 b that mates with an end of a fourth tubular support 150. An end of a sixth tubular support 160 is threadably coupled to the threaded connection 130 f of the second tubular support 130, and another end of the sixth tubular support mates with the interior surface of the lower portion 110 c of the expansion cone launcher 110.

Burst discs 165 a and 165 b are received within the openings 125 ca and 125 cb of the first tubular support member 125 in order to controllably permit fluidic materials to pass from the passage 125 into a first annular region 170 defined by the annular region between the first tubular support member 125, the second tubular support member 130, and the sixth tubular support member 160, the passages 150 a and 150 b, and a second annular region 175 defined by the annular region between the second tubular support 130, the third tubular support 145 and the fifth tubular support 155.

A shoe assembly 180 is coupled to the expansion cone launcher 110 and releasably coupled to the expansion cone assembly 115. The shoe assembly 180 includes a tubular support member 185 that includes a releasable coupling 185 a at an end that is releasably coupled to the releasable coupling 125 d of the first tubular support member 125 and a threaded connection 185 b at another end. In an exemplary embodiment, the releasable coupling 185 a includes a plurality of radial splines that releasably engage the releasable coupling 125 d. In this manner, the connection between the releasable coupling 125 d and the releasable coupling 185 a may transmit torque. The tubular support member 185 further includes an internal passage 185 c for conveying fluidic materials that includes a restriction 185 ca for receiving a conventional wiper plug, or other similar device, and a plurality of radially directed ribs 185 d.

An end of a tubular sealing sleeve 190 includes an annular recess 190 a for receiving the lower portion 110 c of the expansion cone launcher 110, and another end of the sealing sleeve includes a threaded connection 190 b. The interior of sealing sleeve 190 further includes a plurality of radially directed ribs 190 c. The sealing sleeve 190 is coupled to the end of the lower portion 110 c of the expansion cone launcher 110 by a plurality of pinned connections 195. An annular body 200 of a cured cement is positioned between the tubular support member 185 and the sealing sleeve 190. In a preferred embodiment, the sealing sleeve 190 and the annular body 200 are fabricated from materials that may be drilled out using conventional drilling equipment. In an exemplary embodiment, the sealing sleeve 190 and the annular body 200 are fabricated from aluminum and cement, respectively.

An end of a tubular member 205 is coupled to the threaded connection 190 b of the sealing sleeve 190. An end of a conventional tubular coupling 210 is coupled to threaded connection 185 b of the tubular support 185 and another end of the tubular coupling 210 is coupled to a conventional SSR plug set 215 including an upper and lower SSR plugs, 215 a and 215 b. The tubular coupling 210 and the SSR plug set 215 are contained within the tubular member 205. The tubular coupling 210 includes an internal passage 210 a for conveying fluidic materials, and the upper and lower SSR plugs, 215 a and 215 b, include internal passages, 215 aa and 215 ba, respectively, for conveying fluidic materials.

In a preferred embodiment, the apparatus 100 is provided as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S. provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, filed on Feb. 20, 2001; (23) U.S. provisional patent application Ser. No. 60/262,434, filed on Jan. 17, 2001; (24) U.S. provisional patent application Ser. No. 60/259,486, filed on Jan. 3, 2001; and (25) U.S. provisional patent application Ser. No. 60/303,740, filed on Jul. 6, 2001, the disclosures of which are incorporated herein by reference.

Referring to FIGS. 2 a-2 d, during operation, the apparatus 100 is positioned within a wellbore 220 within a subterranean formation 225. The wellbore 220 may include one or more preexisting sections of wellbore casing, and the wellbore 220 may be positioned in any orientation from the vertical to the horizontal. In order to position the apparatus 100 within the wellbore 220, a tubular support 230 having an internal passage 230 a for conveying fluidic materials is coupled to the threaded coupling element 120 a of the tubular coupling 120. During placement of the apparatus 100 within the wellbore 220, fluidic materials 235 within the wellbore that are displaced by the apparatus 100 are conveyed through the fluid passages 215 ba, 215 aa, 210 a, 185 c, 125 a, 120 c, and 230 a to a location above the apparatus 100. In this manner, surge pressures during placement of the apparatus 100 within the wellbore 220 are minimized. In a preferred embodiment, the apparatus 100 is initially positioned within the wellbore 220 with the tubular member 105 in opposing relation to a preexisting section of a wellbore casing. In this manner, the tubular member 105 may be radially expanded into contact with the preexisting wellbore casing.

In an exemplary embodiment, as illustrated in FIG. 2 a, the intermediate section 105 c of the tubular hanger joint 105 includes sealing members, 105 fa and 105 fb, positioned between corresponding pairs of ribs, 105 gaa and 105 gba, and 105 gab and 105 gbb, respectively, for sealing the interface between the intermediate section of the tubular hanger joint and another preexisting structure such as, for example, a wellbore casing. In an exemplary embodiment, the ribs, 105 gaa, 105 gba, 105 gab, and 105 gbb, are formed integrally to the intermediate section 105 c of the tubular hanger joint 105.

Referring to FIGS. 3 a-3 d, once the apparatus 100 has been positioned at the predetermined initial position within the wellbore 220, fluidic materials 240 may then be injected into the apparatus 100 using the passage 230 a. The fluidic materials 240 may then pass through and out of the apparatus 100 using the passages 120 c, 125 a, 185 c, 210 a, 215 aa, and 215 ba. In this manner, the proper functioning of the passages 210 a, 120 c, 125 a, 185 c, 210 a, 215 aa, and 215 ba may be determined. A ball 245, or other similar device, may then be introduced into the fluidic material 240 in order to release the lower SSR plug 215 b in a well known manner.

Referring to FIGS. 4 a-4 d, the upper SSR plug 215 a may then be released in a well known manner by introducing another ball, or other similar device, into the fluidic material 240.

Referring to FIGS. 5 a-5 c, a conventional dart, ball, or other similar device 245 may then be introduced into the fluidic material 240 and positioned in the restriction 185 ca in the passage 185 c of the tubular support 185. In this manner the region above the restriction 185 ca is fluidicly isolated from the region below the restriction. Continued injection of the fluidic material 240 following the placement of the dart 245 in the restriction 185 ca will then increase the operating pressure within the passages 230 a, 120 c, and 125 a upstream of the restriction 185 ca. The increased operating pressure in turn will rupture one or more of the rupture discs, 165 a and 165 b. In this manner, the pressurized fluidic material 240 will flow through the passages 125 ca and 125 cb into the passages 170, 150 a, 150 b, and 175.

Referring to FIGS. 6 a-6 c, the releasable coupling 125 d and the releasable coupling 185 a are then decoupled and the continued pressurization of the fluidic materials 240 displaces the expansion cone assembly 115 away from the shoe assembly 180 in the longitudinal direction. In this manner, the expansion cone launcher 110 and the expandable tubular member 105 are radially expanded and thereby plastically deformed. In a preferred embodiment, the expansion cone launcher 110 and the expandable tubular member 105 are radially expanded into contact with the interior surface of the wellbore 220, or other tubular member such as, for example, a wellbore casing, a pipeline, or a structural support. In a preferred embodiment, the expandable tubular member 105 includes a plurality of expandable tubular members 105 coupled end to end. In several alternative embodiment, the releasable coupling 125 d and the releasable coupling 185 a are then decoupled manually and/or automatically as a function of the operating pressure upstream of the restriction 185 ca.

Referring to FIGS. 7 a-7 c, after the completion of the radial expansion of the expandable tubular member 105 and the expansion cone launcher 110, the expansion cone assembly 115 is removed from the wellbore 220, and the internal elements of the shoe assembly 180 are drilled out.

In a preferred embodiment, the radial expansion of the expandable tubular member 105 and the expansion cone launcher 110 is provided substantially as disclosed in one or more of the following: (1) U.S. patent application Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed on Apr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635, filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No. 60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patent application Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S. provisional patent application Ser. No. 60/159,082, filed on Oct. 12, 1999, (14) U.S. provisional patent application Ser. No. 60/159,039, filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser. No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patent application Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S. provisional patent application Ser. No. 60/165,228, filed on Nov. 12, 1999, (18) U.S. provisional patent application Ser. No. 60/221,443, filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser. No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patent application Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S. provisional patent application Ser. No. 60/237,334, filed on Oct. 2, 2000, (22) U.S. provisional patent application Ser. No. 60/270,007, filed on Feb. 20, 2001; (23) U.S. provisional patent application Ser. No. 60/262,434, filed on Jan. 17, 2001; (24) U.S. provisional patent application Ser. No. 60/259,486, filed on Jan. 3, 2001; and (25) U.S. provisional patent application Ser. No. 60/303,740, filed on Jul. 6, 2001, the disclosures of which are incorporated herein by reference.

Referring to FIGS. 8 a and 8 b, in an alternative embodiment, the apparatus 100 includes an expansion cone assembly 300 that includes a tubular coupling 305 having a conventional threaded coupling element 305 a at one end for coupling the tubular coupling to a conventional support member and a threaded counterbore 305 b at another end for coupling the tubular coupling to an end of a first tubular support 310. The tubular coupling 305 further includes an internal passage 305 c for conveying fluidic materials.

The first tubular support 310 includes an internal passage 310 a for conveying fluidic materials and an annular flange 310 b, openings 310 ca and 310 cb, and a releasable coupling 310 d at another end. A second tubular support 315 includes an opening 315 a at one end for receiving an end of the first tubular support 310, an annular flange 315 b at one end, an annular flange 315 c at another end including longitudinal passages 315 ca and 315 cb and an opening 315 cc for receiving another end of the first tubular support 310, and an annular recess 315 d at the other end.

A first expansion cone retainer 320 includes an opening 320 a for receiving an end of the second tubular support 315 and a counterbore 320 b. The first expansion cone retainer 320 preferably mates with the expansion cone launcher 110. A first expansion cone 325 includes an opening 325 a for receiving the second tubular support 315, an annular recess 325 b, and an annular recess 325 c. The first expansion cone 325 preferably mates with the first expansion cone retainer 320 and the expansion cone launcher 110.

A second expansion cone retainer 330 includes an opening 330 a for receiving the second tubular support 315, an annular recess 330 b, and an annular recess 330 c. A second expansion cone 335 includes an opening 335 a for receiving the second tubular support 315, an annular recess 335 b, and an annular recess 335 c. The second expansion cone 335 preferably mates with the second expansion cone retainer 330 and the expansion cone launcher 110.

A third expansion cone retainer 340 includes a counterbore 340 a for mating with the second expansion cone 335, a counterbore 340 b for mating with the annular recess 315 d of the second tubular support, and an opening 340 c for defining an annular passage 345. Another annular passage 350 is defined by the annular space between the first tubular support 310 and the second tubular support 315.

Burst discs 355 a and 355 b are positioned in the openings 310 ca and 310 cb, respectively, in order to controllably permit pressurized fluidic materials to pass from the passage 310 a into the passages 345, 315 ca, 315 cb, and 350.

It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the apparatus 100 may be used to form and/or repair, for example, a wellbore casing, a pipeline, or a structural support. Furthermore, the burst discs 165 a, 165 b, 355 a, and 355 b may be replaced with conventional pressure relief valves.

Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. 

1. A method of coupling a radially expandable tubular member to a preexisting structure, comprising: positioning the tubular member and an expansion device within the preexisting structure; injecting fluidic materials into the tubular member; sensing the operating pressure of the fluidic materials; and radially expanding the tubular member into contact with the preexisting structure when the sensed operating pressure exceeds a predetermined amount by displacing the expansion device relative to the tubular member.
 2. The method of claim 1, wherein sensing the operating pressure includes: sensing the operating pressure of the fluidic materials within the tubular member.
 3. The method of claim 1, wherein radially expanding the tubular member into contact with the preexisting structure when the sensed operating pressure exceeds a predetermined amount by displacing the expansion device relative to the tubular member, comprises: contacting an inner surface of the tubular member with an outer surface of the expansion device during the displacement of the expansion device.
 4. The method of claim 3, wherein the outer surface of the expansion device is tapered.
 5. The method of claim 1, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member comprises: a tapered portion; a non-tapered portion coupled to an end of the tapered portion; and another non-tapered portion coupled to another end of the tapered portion.
 6. The method of claim 1, wherein the tubular member comprises: a wellbore casing.
 7. The method of claim 1, wherein the tubular member comprises: a pipeline.
 8. The method of claim 1, wherein the tubular member comprises: a structural support.
 9. The method of claim 1, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member comprises: a first tubular portion; a first tapered tubular portion coupled to the first tubular portion; a second tubular portion coupled to the first tapered tubular portion; a second tapered tubular portion coupled to the second tubular portion; and a third tubular portion coupled to the second tapered tubular portion.
 10. The method of claim 9, wherein the outside diameter of the second tubular portion is greater than the outside diameter of the first tubular portion; and wherein the outside diameter of the second tubular portion is greater than the outside diameter of the third tubular portion.
 11. The method of claim 9, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member further comprises: a third tapered tubular portion coupled to the third tubular portion; and a fourth tubular portion coupled to the third tapered tubular portion.
 12. The method of claim 11, wherein the outside diameter of the fourth tubular portion is greater than the outside diameter of the third tubular portion.
 13. An apparatus for coupling a radially expandable tubular member to a preexisting structure, comprising: a first tubular support member including a first internal passage; an expansion cone assembly including: a second tubular support including a second internal passage operably coupled to the first internal passage, one or more radial openings, and a first releasable coupling; one or more pressure relief valves positioned in corresponding ones of the radial openings; and one or more annular expansion cones coupled to the second tubular support; an expansion cone launcher coupled to the annular expansion cones and the radially expandable tubular member; and a shoe assembly, comprising: a third tubular support member including a third internal passage operably coupled to the second internal passage and having a restriction, and a second releasable coupling releasably coupled to the first releasable coupling.
 14. The apparatus of claim 13, wherein the expansion cone assembly includes a plurality of spaced apart annular expansion cones.
 15. The apparatus of claim 13, wherein the expansion cone launcher comprises: a tapered tubular portion.
 16. The apparatus of claim 13, wherein the tubular member comprises: a wellbore casing.
 17. The apparatus of claim 13, wherein the tubular member comprises: a pipeline.
 18. The apparatus of claim 13, wherein the tubular member comprises: a structural support.
 19. A system for coupling a radially expandable tubular member to a preexisting structure, comprising: means for positioning the tubular member and an expansion device within the preexisting structure; means for injecting fluidic materials into the tubular member; means for sensing the operating pressure of the fluidic materials; and means for radially expanding the tubular member into contact with the preexisting structure when the sensed operating pressure exceeds a predetermined amount by displacing the expansion device relative to the tubular member.
 20. The system of claim 19, wherein the means for sensing the operating pressure includes: means for sensing the operating pressure of the fluidic materials within the tubular member.
 21. The system of claim 19, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member comprises: a tapered portion; a non-tapered portion coupled to an end of the tapered portion; and another non-tapered portion coupled to another end of the tapered portion.
 22. The system of claim 19, wherein the tubular member comprises: a wellbore casing.
 23. The system of claim 19, wherein the tubular member comprises: a pipeline.
 24. The system of claim 19, wherein the tubular member comprises: a structural support.
 25. The system of claim 19, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member comprises: a tapered portion; a non-tapered portion coupled to an end of the tapered portion; and another non-tapered portion coupled to another end of the tapered portion.
 26. The system of claim 19, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member comprises: a first tubular portion; a first tapered tubular portion coupled to the first tubular portion; a second tubular portion coupled to the first tapered tubular portion; a second tapered tubular portion coupled to the second tubular portion; and a third tubular portion coupled to the second tapered tubular portion.
 27. The system of claim 26, wherein the outside diameter of the second tubular portion is greater than the outside diameter of the first tubular portion; and wherein the outside diameter of the second tubular portion is greater than the outside diameter of the third tubular portion.
 28. The system of claim 26, wherein, prior to the radial expansion and plastic deformation of the tubular member, the tubular member further comprises: a third tapered tubular portion coupled to the third tubular portion; and a fourth tubular portion coupled to the third tapered tubular portion.
 29. The system of claim 28, wherein the outside diameter of the fourth tubular portion is greater than the outside diameter of the third tubular portion.
 30. An apparatus for coupling a radially expandable tubular member to a preexisting structure, comprising: a first tubular support member including a first internal passage; an expansion device assembly including: a second tubular support including a second internal passage operably coupled to the first internal passage; one or more pressure relief valves operably coupled to the second internal passage; and one or more expansion members movably coupled to the second tubular support adapted to radially expand and plastically deform the radially expandable tubular member as a function of the operation of one or more of the pressure relief valves.
 31. The apparatus of claim 30, wherein one or more of the expansion members comprise annular expansion cones.
 32. A method of coupling a radially expandable pipeline member to a preexisting pipeline member, comprising: positioning the pipeline member and an expansion device within the preexisting pipeline member; injecting fluidic materials into the pipeline member; sensing the operating pressure of the fluidic materials; and radially expanding the pipeline member into contact with the preexisting pipeline member when the sensed operating pressure exceeds a predetermined amount by displacing the expansion device relative to the pipeline member.
 33. An apparatus for coupling a radially expandable pipeline member to a preexisting pipeline member, comprising: a first tubular support member including a first internal passage; an expansion cone assembly including: a second tubular support including a second internal passage operably coupled to the first internal passage, one or more radial openings, and a first releasable coupling; one or more pressure relief valves positioned in corresponding ones of the radial openings; and one or more annular expansion cones coupled to the second tubular support; an expansion cone launcher coupled to the annular expansion cones and the radially expandable pipeline member; and a shoe assembly, comprising: a third tubular support member including a third internal passage operably coupled to the second internal passage and having a restriction, and a second releasable coupling releasably coupled to the first releasable coupling. 